Systems and methods for overmolding on electronic device surfaces

ABSTRACT

An electronic device includes a display with a glass planar portion and a second material position at an outer edge of the glass planar portion. The glass planar portion defines a majority of a display surface of the display, and the second material is molded to the outer edge of the glass planar portion and defines at least part of a border portion. The second material is curved in a direction perpendicular to the display surface. The second material is composed of a first plurality of segments and a second plurality of segments. Each segment of the second plurality of segments is interposed between adjacent segments of the first plurality of segments, and the first plurality of segments interlock with the second plurality of segments.

BACKGROUND Background and Relevant Art

As electronic devices become smaller and lighter, more electronicdevices are primarily operated in a user's hand. The display cover orother external surfaces of the housing of conventional electronicdevices are flat. Abrupt corners of the flat surfaces are touncomfortable in the user's hand. To produce smaller and lighterelectronic devices, the bezel or border around the display iscontinually reduced to more efficiently use the surface area of theelectronic device. Forming a display cover or other housing surface withcurved edges of the panel increases cost. Application of a second bordermaterial around the display cover or other housing surface to create asmooth, curved border introduces stress to the display cover or otherhousing surface during manufacturing and over the lifetime of thedevice, leading to potential damage to the display cover or otherhousing surface.

BRIEF SUMMARY

In some embodiments, an electronic device includes a display with aglass planar portion and a second material position at an outer edge ofthe glass planar portion. The glass planar portion defines a majority ofa display surface of the display, and the second material is molded tothe outer edge of the glass planar portion and defines at least part ofa border portion. The second material is curved in a directionperpendicular to the display surface. The second material is composed ofa first plurality of segments and a second plurality of segments. Eachsegment of the second plurality of segments is interposed betweenadjacent segments of the first plurality of segments, and the firstplurality of segments interlock with the second plurality of segments.

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key features oressential features of the claimed subject matter, nor is it intended tobe used as an aid in determining the scope of the claimed subjectmatter.

Additional features and advantages will be set forth in the descriptionwhich follows, and in part will be obvious from the description, or maybe learned by the practice of the teachings herein. Features andadvantages of the disclosure may be realized and obtained by means ofthe instruments and combinations particularly pointed out in theappended claims. Features of the present disclosure will become morefully apparent from the following description and appended claims or maybe learned by the practice of the disclosure as set forth hereinafter.

BRIEF DESCRIPTION OF THE DRAWINGS

In order to describe the manner in which the above-recited and otherfeatures of the disclosure can be obtained, a more particulardescription will be rendered by reference to specific embodimentsthereof which are illustrated in the appended drawings. For betterunderstanding, the like elements have been designated by like referencenumbers throughout the various accompanying figures. While some of thedrawings may be schematic or exaggerated representations of concepts, atleast some of the drawings may be drawn to scale. Understanding that thedrawings depict some example embodiments, the embodiments will bedescribed and explained with additional specificity and detail throughthe use of the accompanying drawings in which:

FIG. 1-1 is a perspective view of an electronic device, according to atleast one embodiment of the present disclosure;

FIG. 1-2 is a side detail view of the electronic device of FIG. 1-1 ,according to at least one embodiment of the present disclosure;

FIG. 2 is a perspective view of 2D glass, 2.5D glass, and 3D glass,according to at least one embodiment of the present disclosure;

FIG. 3 is a front view of a tablet computer, according to at least oneembodiment of the present disclosure;

FIG. 4 is a front view of a television remote, according to at least oneembodiment of the present disclosure;

FIG. 5 is a top view of a body panel with a segmented border portion,according to at least one embodiment of the present disclosure;

FIG. 6 is a side cross-sectional view of a body panel with a curvedborder portion, according to at least one embodiment of the presentdisclosure;

FIG. 7 is a flowchart illustrating a method of manufacturing anelectronic device, according to at least one embodiment of the presentdisclosure;

FIG. 8 is a front view of a body panel with a first plurality ofsegments of a border portion, according to at least one embodiment ofthe present disclosure; and

FIG. 9 is a front view of the body panel of FIG. 8 with a secondplurality of segments of the border portion, according to at least oneembodiment of the present disclosure.

DETAILED DESCRIPTION

The present disclosure relates generally to systems and methods forproviding a body panel for an electronic device with a curved borderportion. More particularly, this disclosure relates to a body panelconsisting of a first material connected to a border portion consistingof a second material different from the first. The border portion isformed and applied to the first material in segments during assembly toalleviate stress in the first material associated with contraction ofthe second material related to cooling and/or curing of the secondmaterial. The contraction of the second material around the body panelcan damage the body panel, itself, and the residual stress associatedwith the contraction can render the body panel more susceptible todamage during use or transport of the device.

In some embodiments, an electronic device has at least one substantiallyplanar body panel that comprises a portion of a first surface of thedevice. In some embodiments, the body panel comprises a majority of thefirst surface of the device. In some embodiments, the electronic devicehas a complementary second body panel that is substantially planar thatcomprises a portion of a second surface of the device. In someembodiments, the electronic device has a complementary second body panelthat is substantially planar and comprises a majority of the secondsurface of the device. In some embodiments, the first body panel and thesecond body panel are parallel to one another. In some embodiments, thefirst surface is a top surface and the second surface is a bottomsurface. In some embodiments, the first surface is a front surface andthe second surface is a back surface.

FIGS. 1-1 and 1-2 illustrate an embodiment of an electronic device 100with a display cover 102 on a first surface and a metal body panel 108on an opposite second surface. FIG. 1-1 is a perspective view of thedisplay cover 102 defining the planar portion 104 of the electronicdevice 100 that is bounded by the border portion 106. FIG. 1-2 is a sideview of the electronic device 100 of FIG. 1-1 showing border portions106 positioned at the edges of the planar portions 104, defined by thedisplay cover 102 and a metal body panel 108. The border portions 106provide a curved and continuous surface to the electronic device 100from the planar portion 104 of the display cover 102 around the side ofthe electronic device 100 to the planar portion 104 of the metal bodypanel 108 on the back of the electronic device 100.

The body panel that forms a portion or a majority of the first surfaceis, in some embodiments, entirely planar. In some embodiments, the bodypanel is substantially planar in that at least 90% of a surface of thebody panel lies in a single plane or within a 10% deviation from theplane. FIG. 2 illustrates examples of planar or substantially planarglass pieces. In some embodiments, the planar portion 204-1 of theelectronic device is entirely planar, such as two-dimensional (2D)glass. In some embodiments, the planar portion 204-2, 204-3 of theelectronic device has a curved region adjacent the flat surface, such asthe 2.5D and 3D glass illustrated in FIG. 2 . In some embodiments, thefirst surface of the electronic device has a non-planar portion that isseparate from the display cover or other body panel, such as a keyboard,trackball, touchpad, other physical input mechanism, a textured grip,other raised or recessed portion, or other continuous or discontinuousregion that is not coplanar with the planar portion of the firstsurface.

In a portable electronic device, the device is commonly held in theuser's hand. A curved side of the electronic device can be morecomfortable for a user to hold. A planar body panel may be substantiallycheaper and easier to manufacture than a curved body panel. In someembodiments, a border portion that joins the planar body panel toanother part of the electronic device housing (e.g., a side panel, acomplementary second body panel, or a bucket that contains electroniccomponents) can reduce costs, simplify assembly, allow additionalproduct design options, or combinations thereof. In some embodiments, aborder portion that joins the planar body panel to another part of theelectronic device housing can visually blend the border portion with theplanar portion and give the planar portion a curved appearance to auser.

A continuous border portion in a conventional electronic device canapply a compressive or shear force to the body panel as the material ofthe border portion contracts due to cooling or curing of the secondmaterial over time. A segmented border portion according to the presentdisclosure reduces the forces applied to the body panel, allowing largerarea and/or thinner body panels to be used. In some embodiments, theborder portion is applied to an outer edge of the body panel. In someembodiments, the border portion is overmolded on the body panel. In someembodiments, at least part of the border portion is applied to a planarsurface of the body panel. In some embodiments, the border portion ispositioned around a complete outer edge (i.e. perimeter) of the bodypanel. In some embodiments, the border portion is positioned around lessthan the complete outer edge of the body panel.

In some embodiments, the electronic device is a mobile electronicdevice, such as a smartphone or personal media device; a portablecomputer, such as a hybrid computer, a laptop computer, or a tabletcomputer; a display, such as a computer monitor, a television, or avideo conference device; a household appliance; or another electronicdevice in which aesthetic appearance is a concern, such as automotiveinfotainment systems.

In some embodiments, the body panel is a display cover over a display ofthe electronic device. For example, the body panel may be glass,tempered glass, acrylic or other transparent panel material. Inembodiments of an electronic device with a display cover, a segmentedborder portion reduces the forces on the glass or other transparentmaterial to limit and/or prevent fractures or breakage of the displaycover. For example, a glass display cover can fracture under acompressive force, or the stress from the compressive force can make theglass display cover more prone to cracking or breaking during transportor use of the electronic device, even if the display cover does notbreak immediately after manufacturing. In some embodiments, the bodypanel is a metal, such as aluminum, magnesium, iron, titanium, or alloysincluding such metals. In embodiments of an electronic device with ametal body panel having a border portion applied thereto, compressiveforces from the cooling and/or curing of the material of the borderportion can produce cracks, buckles, or other distortions to the metalbody panel.

Some embodiments of electronic devices according to the presentdisclosure have a body panel with a border portion positioned around acomplete outer edge of the body panel. For example, a television mayhave a border portion that is positioned around the complete outer edgeof the display glass. FIG. 3 is a front view of an electronic device 300with a complete border portion 306. In some embodiments, a tablet has aplanar portion 304 that defines a majority of the first surface, and theborder portion 306 is positioned around the entire outer edge 310 of theplanar portion 304. The display cover of the planar portion experiencedgreater stress due to manufacturing with a conventional border portionthan a border portion according to the present disclosure.

In some embodiments, a body panel has a border portion applied to a partof the outer edge. FIG. 4 is a front view of an electronic device 400with a partial border portion 406. In some embodiments, an electronicdevice 400, such as a television remote, has a display glass or otherplanar portion 404 positioned on the upper portion of a top surface ofthe remote with physical buttons located on a lower portion of the topsurface, and the border portion 406 may be applied around three sides ofthe outer edge 410 of the planar portion 404 with no border portion 406proximate the lower portion containing buttons.

A border portion includes a second material, in some embodiments, thatis different from a first material of the planar body panel. In someembodiments, the second material includes a polymer. In someembodiments, the second material includes a polymer with a glass fill,such as D251 (20% glass fill), D151 (10% glass fill), or D551 (50% glassfill) available from SABIC Plastics. The second material is positionedat the outer edge of the body panel and is composed of a first pluralityof segments and a second plurality of segments that are joined to oneanother at seams therebetween. In some embodiments, each segment of thesecond plurality of segments is interposed between adjacent segments ofthe first plurality of segments. In some embodiments, at least onesegment of the border portion includes a third material, different fromthe second material. The third material can provide different oradditional material properties from the second material.

Referring now to FIG. 5 , some embodiments of an electronic device 500according to the present disclosure have a segmented border portion 506.In some embodiments, a segmented border portion 506 is formed in twostages with a first plurality of segments 512-1 formed first, and asecond plurality of segments 512-2 positioned in spaces between thesegments of the first plurality of segments 512-1. The first pluralityof segments 512-1 and second plurality of segments 512-2 are joined atseams 514 at lateral edges of the segments by adherence and/ormechanical locking of the segments.

In some embodiments, the second material has a higher strength than thethird material, and the third material is positioned at the corners ofthe device to provide shock absorption. In some embodiments, the thirdmaterial has greater radiotransparency than the second material, and asegment of the third material is positioned adjacent and/or covering aradio frequency (RF) antenna of the electronic device, such that the RFantenna can transmit and receive RF signals through the RF windowcreated by the segment of third material. For example, the secondmaterial may be D551 (polycarbonate material with 50% glass fiber) andthe third material may be D151 (polycarbonate material with 10% glassfiber by Sabic).

In some embodiments, such as that illustrated in FIG. 5 , interlocksbetween segments can provide additional strength to the seams 514. Insome embodiments, the interlocks are mechanical interlocks that inhibitthe movement of a first segment relative to a second segment at the seam514. For example, the interlocks may include complementary structuresthat mate together to limit and/or prevent relative movement, such as aprotrusion and complementary recess, a dovetail and complementary pins,sawtooth patterns, irregular patterns, or other surface textures. Insome embodiments, a mechanical interlock can limit and/or preventrelative movement in one direction transverse to the seam 514, such as adovetail. In some embodiments, a mechanical interlock can limit and/orprevent relative movement in two directions transverse to the seam 514,such as a fully captured post. In some embodiments, the interlocksincrease a surface area of the seam 514, providing greater contactsurface for the first segment and second segment to bond or adhere toone another.

In some embodiments, different materials in the border portion canprovide additional or different functionality while maintaining anappearance of a single seamless border portion. For example, a borderportion can include a segment with a softer or more elastic material toallow the inclusion of a physical button in the border portion. In someembodiments, a physical button (e.g., a button that is actuated bydepressing the button) is located underneath an outer surface of theborder portion, and the physical button is actuatable by elasticallydeforming the segment contacting the physical button.

In some embodiments, a border portion can include a segment configuredto allow the inclusion of haptic feedback in the border portion. In someembodiments, a segment is located contacting a motor or actuator (suchas a linear actuator, vibration motor, or piezoelectric motor) thatprovides haptic feedback, and the segment transmits the hapticinformation to the user.

In some embodiments, the border portion includes a segment withelectrically conductive material to allow touch-sensitive controlsembedded in or below the border portion. In some embodiments, atouch-sensitive button (e.g., a capacitive touch surface) is locatedunderneath a segment of the outer surface of the border portion, and thetouch-sensitive button is activatable by a user touching, or pressingon, the segment.

A border portion can have a continuous or discontinuous profile.Referring now to FIG. 6 , in some embodiments, an outer surface 616 ofat least one segment of the border portion 606 is continuous with theouter surface 616 of the planar portion 604, such that the outer surface616 of the segment provides the appearance of a continuous surface withthe planar portion 604 where the segment contacts the outer edge 610 ofthe planar portion 604. In some embodiments, an outer surface of atleast one segment of the border portion is discontinuous with the outersurface of the planar portion, such that the outer surface of thesegment is oriented at a different angle from the planar portion wherethe segment contacts the outer edge of the planar portion.

In some embodiments, at least one segment of the border portion 606 hasa curved edge profile. In some embodiments, the curved profile has aconstant radius of curvature, such as illustrated in FIG. 6 . In someembodiments, the curved profile has a decreasing radius of curvatureaway from the planar portion. In some embodiments, the curved profilehas an increasing radius of curvature away from the planar portion. Insome embodiments, at least one segment of the border portion has adiscontinuous profile, such as a beveled or chamfered profile.

The segmented border portion is applied to the planar body panel in atleast two stages. In some embodiments, a method 718 of manufacturing anelectronic device includes obtaining (720) a planar or substantiallyplanar body panel including a first material and applying (722) a firstplurality of segments to an outer edge of the body panel. In someembodiments, the first plurality of segments includes a second materialdifferent from the first material. For example, the first material maybe glass and the second material may be a polymer.

In some embodiments, the second material facilitates injection moldingor another application of the second material at an elevatedtemperature. In some embodiments, a mask is positioned proximate and/oradjacent to the outer edge of the body panel and a first shot of thesecond material is molded to the outer edge in the area around the maskand abutting the mask, such that when the mask is removed, the lateraledges of the first plurality of segments are defined by the mask shape.

The method further includes applying (724) a second plurality ofsegments to the outer edge of the body panel. In some embodiments, thesecond plurality of segments are positioned in the spaces between thesegments of the first plurality of segments. In some embodiments, thesegments of the second plurality of segments each contact at least oneof the segments of the first plurality of segments at the lateral edgeof the segments to form seams therebetween. In some embodiments, thesecond plurality of segments fill the spaces between the segments of thefirst plurality of segments, and the first plurality of segments andsecond plurality of segments produce a continuous border portion.

In some embodiments, the border portion is positioned around the entireouter edge of the body panel. In some embodiments, the border portion ispositioned on less than the entire outer edge of the body panel. In someembodiments, the border portion is less than 90% of the entire outeredge of the body panel. In some embodiments, the border portion is lessthan 75% of the entire outer edge of the body panel. In someembodiments, the border portion is less than 50% of the entire outeredge of the body panel.

FIGS. 8 and 9 illustrate the two stages of the application process ofthe method 718 described in relation to FIG. 7 . FIG. 8 illustrates abody panel comprising a planar portion 804 and border portion with onlya first plurality of segments 812-1. The first plurality of segments812-1 is applied to the outer edge 810 of the planar portion 804. Thesegments of the first plurality of segments 812-1 are formed by maskingoff the regions between the segments, and upon removal of the mask, thefirst plurality of segments 812-1 is left with spaces 826 therebetween.

FIG. 9 shows the body panel of FIG. 8 with the complete border portion806 around the outer edge 810 of the planar portion 804. In someembodiments, the first plurality of segments 812-1 and second pluralityof segments 812-2 are positioned on equal lengths of the outer edge 810of the planar portion 804. In some embodiments, the first plurality ofsegments 812-1 and second plurality of segments 812-2 are positioned ondifferent lengths of the outer edge 810 of the planar portion 804. Insome embodiments, the first plurality of segments 812-1 is positioned onless than 90% of the outer edge 810 of the planar portion 804. In someembodiments, the first plurality of segments 812-1 is positioned on lessthan 75% of the outer edge 810 of the planar portion 804. In someembodiments, the first plurality of segments 812-1 is positioned on lessthan 50% of the outer edge 810 of the planar portion 804.

In some embodiments, the first plurality of segments and secondplurality of segments are positioned on equal lengths of the borderportion when the border portion is positioned on less than the entireouter edge of the body panel. In some embodiments, the first pluralityof segments and second plurality of segments are positioned on differentlengths of the border portion when the border portion is positioned onless than the entire outer edge of the body panel. In some embodiments,the first plurality of segments is positioned on less than 90% of theborder portion. In some embodiments, the first plurality of segments ispositioned on less than 75% of the border portion. In some embodiments,the first plurality of segments is positioned on less than 50% of theborder portion. In some embodiments, the second plurality of segmentsfills the spaces between the first plurality of segments. For example,the second plurality of segments is positioned along 10% of the borderportion when the first plurality of segments is positioned along 90%.

In some embodiments, the first plurality of segments contract due tocooling from an elevated application temperature to an ambienttemperature and/or due to curing of the second material over time.Therefore, the compression force to the body panel related to thecontraction of the second material can be reduced by allowing the firstplurality of segments to cool and contract prior to application of thesecond plurality of segments. The compression force can be reducedproportionally to the ratio of a length of the first plurality ofsegments (which are contracted) prior to the application of the secondplurality of segments. In some embodiments, a 1:1 ratio of borderportion length of the first plurality of segments to the secondplurality of segments reduces the compressive force on the body panel byapproximately 50%.

In some embodiments, the method further includes allowing the firstplurality of segments to cool from a first temperature to a secondtemperature before applying the second plurality of segments. In someembodiments, the first temperature is the injection temperature of thesecond material when injection molded around the mask, and the secondtemperature is below 130° C. In some embodiments, the first temperatureis the injection temperature of the second material when injectionmolded around the mask, and the second temperature is below 90° C.

In some embodiments, the adherence of segments and/or mechanical lockingof the border portion 806 to the outer edge 810 of the planar portion804 can be improved by priming or etching of the outer edge 810 prior toapplication of the second material. In some embodiments, the methodincludes altering the outer edge 810 to increase surface area. In someembodiments, the outer edge 810 is chemically etched to increase thesurface relief and, therefore, the surface area of the outer edge 810.In some embodiments, the outer edge 810 is mechanically etched toincrease the surface relief and, therefore, the surface area of theouter edge 810. In some embodiments, the outer edge 810 is laser etchedto increase the surface relief and, therefore, the surface area of theouter edge 810. In some embodiments, the outer edge 810 is ion-etched orplasma treated to increase the surface relief and, therefore, thesurface area of the outer edge 810.

In some embodiments, the adherence or interlock between segments of thefirst plurality of segments 812-1 and segments of the second pluralityof segments 812-2 can be improved by preparation of the lateral surfacesat the seams 814. In some embodiments, the lateral surface is primed ina similar manner to the outer edge. In some embodiments, the lateralsurface(s) is primed in a different manner. In some embodiments, thelateral surface(s) is chemically etched to increase the surface reliefand, therefore, the surface area of the lateral surface(s). In someembodiments, the lateral surface(s) is mechanically etched to increasethe surface relief and, therefore, the surface area of the lateralsurface(s). In some embodiments, the lateral surface(s) is laser etchedto increase the surface relief and, therefore, the surface area of thelateral surface(s). In some embodiments, the lateral surface(s) ision-etched to increase the surface relief and, therefore, the surfacearea of the lateral surface(s).

In some embodiments where the second plurality of segments does notentirely fill the spaces between the segments of the first plurality ofsegments, the method further includes applying at least one additionalsegment. In some embodiments, the at least one additional segment is athird plurality of segments. In some embodiments, the at least oneadditional segment is a single segment of a third material differentfrom the second material, such as a radiotransparent material to createan RF window in the border portion. In some embodiments, the at leastone additional segment includes corner segments and a third materialwith greater elasticity than the second material to provide shockabsorption at the corners of the electronic device.

INDUSTRIAL APPLICABILITY

The present disclosure relates generally to systems and methods forproviding a body panel for an electronic device with a curved borderportion. More particularly, this disclosure relates to a body panelconsisting of a first material connected to a border portion consistingof a second material different from the first. The border portion isformed and applied to the first material in segments during assembly toalleviate stress in the first material and second material associatedwith contraction of the second material related to cooling and/or curingof the second material.

In some embodiments, an electronic device has at least one substantiallyplanar body panel that comprises a portion of a first surface of thedevice. In some embodiments, the body panel comprises a majority of thefirst surface of the device. In some embodiments, the electronic devicehas a complementary second body panel that is substantially planar thatcomprises a portion of a second surface of the device. In someembodiments, the electronic device has a complementary second body panelthat is substantially planar and comprises a majority of the secondsurface of the device. In some embodiments, the first body panel and thesecond body panel are parallel to one another. In some embodiments, thefirst surface is a top surface and the second surface is a bottomsurface. In some embodiments, the first surface is a front surface andthe second surface is a back surface.

The body panel that forms a portion or a majority of the first surfaceis, in some embodiments, entirely planar. In some embodiments, the bodypanel is substantially planar in that at least 90% of a surface of thebody panel lies in a single plane or within a 10% deviation from theplane. In some embodiments, the first surface of the electronic deviceis entirely planar. In some embodiments, the first surface of theelectronic device has a non-planar portion, such as a keyboard,trackball, touchpad, other physical input mechanism, a textured grip,other raised or recessed portion, or other continuous or discontinuousregion that is not coplanar with the planar portion of the firstsurface.

In a portable electronic device, the device is commonly held in theuser's hand. A curved side of the electronic device can be morecomfortable for a user to hold. A planar body panel may be substantiallycheaper and easier to manufacture than a curved body panel. In someembodiments, a border portion that joins the planar body panel toanother part of the electronic device housing (e.g., a side panel, acomplementary second body panel, or a bucket that contains electroniccomponents) can reduce costs, simplify assembly, allow additionalproduct design options, or combinations thereof. In some embodiments, aborder portion that joins the planar body panel to another part of theelectronic device housing can visually blend the border portion with theplanar portion and give the planar portion a curved appearance to auser.

A continuous border portion in a conventional electronic device canapply a compressive or shear force to the body panel as the material ofthe border portion contracts due to cooling or curing of the secondmaterial over time. A segmented border portion according to the presentdisclosure reduces the forces applied to the body panel, allowing largerarea and/or thinner body panels to be used. In some embodiments, theborder portion is applied to an outer edge of the body panel. In someembodiments, the border portion is overmolded on the body panel. In someembodiments, at least part of the border portion is applied to a planarsurface of the body panel. In some embodiments, the border portion ispositioned around a complete outer edge (i.e. perimeter) of the bodypanel. In some embodiments, the border portion is positioned around lessthan the complete outer edge of the body panel.

In some embodiments, the electronic device is a mobile electronicdevice, such as a smartphone or personal media device; a portablecomputer, such as a hybrid computer, a laptop computer, or a tabletcomputer; a display, such as a computer monitor, a television, or avideo conference device; a household appliance; or another electronicdevice in which aesthetic appearance is a concern, such as automotiveinfotainment systems.

In some embodiments, the body panel is a display cover over a display ofthe electronic device. For example, the body panel may be glass,tempered glass, acrylic or other transparent panel material. Inembodiments of an electronic device with a display cover, a segmentedborder portion reduces the forces on the glass or other transparentmaterial to limit and/or prevent fractures or breakage of the displaycover. For example, a glass display cover can fracture under acompressive force, or the stress from the compressive force can make theglass display cover more prone to cracking or breaking during transportor use of the electronic device, even if the display cover does notbreak immediately after manufacturing. In some embodiments, the bodypanel is a metal, such as aluminum, magnesium, iron, titanium, or alloysincluding such metals. In embodiments of an electronic device with ametal body panel having a border portion applied thereto, compressiveforces from the cooling and/or curing of the material of the borderportion can produce cracks, buckles, or other distortions to the metalbody panel when the body panel is thin, such as less than 1.0 mm thick,less than 0.8 mm thick, or less than 0.6 mm thick.

Some embodiments of electronic devices according to the presentdisclosure have a body panel with a border portion positioned around acomplete outer edge of the body panel. For example, a television mayhave a border portion that is positioned around the complete outer edgeof the display glass. In some embodiments, a body panel has a borderportion applied to a part of the outer edge. For example, a televisionremote may have a display glass positioned on the upper portion of a topsurface of the remote with physical buttons located on a lower portionof the top surface, and the border portion may be applied around threesides of the display glass with no border portion proximate the lowerportion containing buttons.

A border portion includes a second material, in some embodiments, thatis different from a first material of the planar body panel. In someembodiments, the second material includes a polymer. In someembodiments, the second material includes a polymer with a glass fill,such as D251 (20% glass fill), D151 (10% glass fill), or D551 (50% glassfill) available from SABIC Plastics. The second material is positionedat the outer edge of the body panel and is composed of a first pluralityof segments and a second plurality of segments that are joined to oneanother at seams therebetween. In some embodiments, each segment of thesecond plurality of segments is interposed between adjacent segments ofthe first plurality of segments. In some embodiments, at least onesegment of the border portion includes a third material, different fromthe second material. The third material can provide different oradditional material properties from the second material.

In some embodiments, the second material has a higher strength than thethird material, and the third material is positioned at the corners ofthe device to provide shock absorption. In some embodiments, the thirdmaterial has greater radiotransparency than the second material, and asegment of the third material is positioned adjacent and/or covering anRF antenna of the electronic device, such that an RF antenna cantransmit and receive RF signals through the RF window created by thesegment of third material. For example, the second material may be D551and the third material may be D151.

Interlocks between segments can provide additional strength to the seamsbetween the segments. In some embodiments, the interlocks are mechanicalinterlocks that inhibit the movement of a first segment relative to asecond segment at the seam. For example, the interlocks may includecomplementary structures that mate together to limit and/or preventrelative movement, such as a protrusion and complementary recess, adovetail and complementary pins, sawtooth patterns, irregular patterns,or other surface textures. In some embodiments, a mechanical interlockcan limit and/or prevent relative movement in one direction transverseto the seam, such as a dovetail. In some embodiments, a mechanicalinterlock can limit and/or prevent relative movement in two directionstransverse to the seam, such as a fully captured post. In someembodiments, the interlocks increase a surface area of the seam,providing greater contact surface for the first segment and secondsegment to bond or adhere to one another.

In some embodiments, different materials in the border portion canprovide additional or different functionality while maintaining anappearance of a single seamless border portion. For example, a borderportion can include a segment with a softer or more elastic material toallow the inclusion of a physical button in the border portion. In someembodiments, a physical button (e.g., a button that is actuated bydepressing the button) is located underneath an outer surface of theborder portion, and the physical button is actuatable by elasticallydeforming the segment contacting the physical button.

In some embodiments, a border portion can include a segment with asofter or more elastic material to allow the inclusion of hapticfeedback in the border portion. In some embodiments, a segment islocated contacting a motor or actuator (such as a linear actuator,vibration motor, or piezoelectric motor) that provides haptic feedback,and the segment transmits the haptic information to the user.

In some embodiments, the border portion includes a segment withelectrically conductive material to allow touch-sensitive controlsembedded in or below the border portion. In some embodiments, atouch-sensitive button (e.g., a capacitive touch surface) is locatedunderneath an outer surface of the border portion, and the physicalbutton is actuatable by touching the segment contacting the physicalbutton.

A border portion can have a continuous or discontinuous profile. In someembodiments, an outer surface of at least one segment of the borderportion is continuous with the outer surface of the planar portion, suchthat the outer surface of the segment provides the appearance of acontinuous surface with the planar portion where the segment contactsthe outer edge of the planar portion. In some embodiments, an outersurface of at least one segment of the border portion is discontinuouswith the outer surface of the planar portion, such that the outersurface of the segment is oriented at a different angle from the planarportion where the segment contacts the outer edge of the planar portion.

In some embodiments, at least one segment of the border portion has acurved edge profile. In some embodiments, the curved profile has aconstant radius of curvature. In some embodiments, the curved profilehas a decreasing radius of curvature away from the planar portion. Insome embodiments, the curved profile has an increasing radius ofcurvature away from the planar portion. In some embodiments, at leastone segment of the border portion has a discontinuous profile, such as abeveled or chamfered profile.

The segmented border portion is applied to the planar body panel in atleast two stages. In some embodiments, a method of manufacturing anelectronic device includes obtaining a planar or substantially planarbody panel including a first material and applying a first plurality ofsegments to an outer edge of the body panel. In some embodiments, thefirst plurality of segments includes a second material different fromthe first material. For example, the first material may be glass and thesecond material may be a polymer.

In some embodiments, the second material facilitates injection moldingor another application of the second material at an elevatedtemperature. In some embodiments, a mask is positioned proximate and/oradjacent to the outer edge of the body panel and a first shot of thesecond material is molded to the outer edge in the area around the maskand abutting the mask, such that when the mask is removed, the lateraledges of the first plurality of segments are defined by the mask shape.

The method further includes applying a second plurality of segments tothe outer edge of the body panel. In some embodiments, the secondplurality of segments are positioned in the spaces between the segmentsof the first plurality of segments. In some embodiments, the segments ofthe second plurality of segments each contact at least one of thesegments of the first plurality of segments at the lateral edge of thesegments to form seams therebetween. In some embodiments, the secondplurality of segments fill the spaces between the segments of the firstplurality of segments, and the first plurality of segments and secondplurality of segments produce a continuous border portion.

In some embodiments, the border portion is positioned around the entireouter edge of the body panel. In some embodiments, the border portion ispositioned on less than the entire outer edge of the body panel. In someembodiments, the border portion is less than 90% of the entire outeredge of the body panel. In some embodiments, the border portion is lessthan 75% of the entire outer edge of the body panel. In someembodiments, the border portion is less than 50% of the entire outeredge of the body panel.

In some embodiments, the first plurality of segments and secondplurality of segments are positioned on equal lengths of the outer edgeof the body panel. In some embodiments, the first plurality of segmentsand second plurality of segments are positioned on different lengths ofthe outer edge of the body panel. In some embodiments, the firstplurality of segments is positioned on less than 90% of the outer edgeof the body panel. In some embodiments, the first plurality of segmentsis positioned on less than 75% of the outer edge of the body panel. Insome embodiments, the first plurality of segments is positioned on lessthan 50% of the outer edge of the body panel.

In some embodiments, the first plurality of segments and secondplurality of segments are positioned on equal lengths of the borderportion when the border portion is positioned on less than the entireouter edge of the body panel. In some embodiments, the first pluralityof segments and second plurality of segments are positioned on differentlengths of the border portion when the border portion is positioned onless than the entire outer edge of the body panel. In some embodiments,the first plurality of segments is positioned on less than 90% of theborder portion. In some embodiments, the first plurality of segments ispositioned on less than 75% of the border portion. In some embodiments,the first plurality of segments is positioned on less than 50% of theborder portion. In some embodiments, the second plurality of segmentsfills the spaces between the first plurality of segments. For example,the second plurality of segments is positioned along 10% of the borderportion when the first plurality of segments is positioned along 90%.

In some embodiments, the first plurality of segments contract due tocooling from an elevated application temperature to an ambienttemperature and/or due to curing of the second material over time.Therefore, the compression force to the body panel related to thecontraction of the second material can be reduced by allowing the firstplurality of segments to cool and contract prior to application of thesecond plurality of segments. The compression force can be reducedproportionally to the ratio of a length of the first plurality ofsegments (which are contracted) prior to the application of the secondplurality of segments. In some embodiments, a 1:1 ratio of borderportion length of the first plurality of segments to the secondplurality of segments reduces the compressive force on the body panel byapproximately 50%.

In some embodiments, the method further includes allowing the firstplurality of segments to cool from a first temperature to a secondtemperature before applying the second plurality of segments. In someembodiments, the first temperature is the injection temperature of thesecond material when injection molded around the mask, and the secondtemperature is below 130° C. In some embodiments, the first temperatureis the injection temperature of the second material when injectionmolded around the mask, and the second temperature is below 90° C.

In some embodiments, the adherence of segments and/or mechanical lockingof the border portion to the outer edge of the body panel can beimproved by priming or etching of the outer edge prior to application ofthe second material. In some embodiments, the method includes alteringthe outer edge to increase surface area. In some embodiments, the outeredge is chemically etched to increase the surface relief and, therefore,the surface area of the outer edge. In some embodiments, the outer edgeis mechanically etched to increase the surface relief and, therefore,the surface area of the outer edge. In some embodiments, the outer edgeis laser etched to increase the surface relief and, therefore, thesurface area of the outer edge. In some embodiments, the outer edge ision-etched or plasma-treated to increase the surface relief and,therefore, the surface area of the outer edge.

In some embodiments, the adherence or interlock between segments of thefirst plurality of segments and segments of the second plurality ofsegments can be improved by preparation of the lateral surfaces at theseams. In some embodiments, the lateral surface is primed in a similarmanner to the outer edge. In some embodiments, the lateral surface(s) isprimed in a different manner. In some embodiments, the lateralsurface(s) is chemically etched to increase the surface relief and,therefore, the surface area of the lateral surface(s). In someembodiments, the lateral surface(s) is mechanically etched to increasethe surface relief and, therefore, the surface area of the lateralsurface(s). In some embodiments, the lateral surface(s) is laser etchedto increase the surface relief and, therefore, the surface area of thelateral surface(s). In some embodiments, the lateral surface(s) ision-etched to increase the surface relief and, therefore, the surfacearea of the lateral surface(s).

In some embodiments where the second plurality of segments does notentirely fill the spaces between the segments of the first plurality ofsegments, the method further includes applying at least one additionalsegment. In some embodiments, the at least one additional segment is athird plurality of segments. In some embodiments, the at least oneadditional segment is a single segment of a third material differentfrom the second material, such as a radiotransparent material to createan RF window in the border portion. In some embodiments, the at leastone additional segment includes corner segments and a third materialwith greater elasticity that the second material to provide shockabsorption at the corners of the electronic device.

The present disclosure describes electronic devices and methods ofmanufacturing electronic devices with improved aesthetics and comfortwhile enabling the use of larger body panels with increased durabilityand/or portability. The present disclosure relates to systems andmethods for providing a body panel for an electronic device with asegmented border portion according to at least the examples provided inthe sections below:

1. An electronic device (e.g., 100) comprising:

-   -   a display cover (e.g., 102) including a glass planar portion        (e.g., 104) including a first material, and a second material        positioned at an outer edge (e.g., 310) of the glass planar        portion, wherein:        -   the glass planar portion defines a majority of a display            surface, and        -   the second material is molded to the outer edge of the glass            planar portion and defines at least part of a border portion            (e.g., 606) that is curved in a direction perpendicular to            the display surface (e.g., outer surface 616), wherein the            second material is composed of a first plurality of segments            (e.g., 512-1) and a second plurality of segments (e.g.,            512-2), and wherein each segment of the second plurality of            segments is interposed between adjacent segments of the            first plurality of segments, and wherein the first plurality            of segments interlock (e.g., seam 514) with the second            plurality of segments.

2. The electronic device of section 1, wherein a material composition ofthe first plurality of segments is different than a material compositionof the second plurality of segments.

3. The electronic device of section 1 or 2, wherein each segment of thefirst plurality of segments and the second plurality of segmentsincludes one or more interlocking features to facilitate the firstplurality of segments interlocking with the second plurality ofsegments.

4. The electronic device of any preceding section, wherein the displayis a touch-sensitive display.

5. The electronic device of section 4, wherein a touch-sensitive regionof the touch-sensitive display includes at least part of the borderportion.

6. The electronic device of any preceding section, wherein at least onesegment of the second material is coupled to electronic circuitry of theelectronic device and configured to provide physical buttonfunctionality.

7. The electronic device of any preceding section, further comprising aradio frequency antenna, wherein at least one segment of the secondmaterial is radiotransparent and wherein the antenna is locatedproximate the radiotransparent segment.

8. The electronic device of any preceding section, further comprising ahousing (e.g., metal body panel 108), wherein the second materialconnects the glass planar portion to the housing.

9. A method of manufacturing the display of section 1, the methodcomprising:

-   -   obtaining (720) the glass planar portion;    -   applying (722) the first plurality of segments to the outer edge        of the glass planar portion, the first plurality of segments        having spaces positioned between adjacent segments of the first        plurality of segments; and    -   after applying the first plurality of segments, applying (724)        the second plurality of segments to the outer edge, the second        plurality of segments being positioned in the spaces between the        segments of the first plurality of segments, wherein the first        plurality of segments and second plurality of segments form the        border portion of the display.

10. The method of section 9, wherein applying the first plurality ofsegments includes applying the first plurality of segments at a firsttemperature; and

-   -   the method further comprises, before applying the second        plurality of segments, allowing the first plurality of segments        to cool to a second temperature, wherein the first plurality of        segments contracts when cooling to the second temperature, and        wherein the segments of the second plurality of segments are        sized to interlock with the first plurality of segments after        the contraction.

11. The method of section 9 or 10, further comprising altering the outeredge of the glass pane before applying the first plurality of segments.

12. The method of any of sections 9-11, further comprising altering alateral edge of the first plurality of segments before applying thesecond plurality of segments.

13. An electronic device body panel comprising:

-   -   a planar portion (e.g., 804) including a first material, wherein        the planar portion has an outer edge (e.g., 810),    -   a border portion (e.g., 806) connected to the planar portion        along at least part of the outer edge of the planar portion, the        border portion composed of a second material different from the        first material, wherein the border portion includes:        -   a first plurality of segments (e.g., 812-1) directly            connected to the outer edge, and        -   a second plurality of segments (e.g., 812-2) directly            connected to the outer edge, wherein each segment of the            second plurality of segments is interposed between segments            of the first plurality of segments, and wherein each segment            of the second plurality of segments meets an adjacent            segment of the first plurality of segments at a            corresponding seam (e.g., 814).

14. The body panel of section 13, wherein the first material is glass.

15. The body panel of section 13 or 14, wherein the second material is apolymer.

16. The body panel of any of sections 13-15, wherein each seam includesan interlock between the corresponding segments.

17. The body panel of any of sections 13-16, wherein the secondplurality of segments is radiotransparent.

18. The body panel of any of sections 13-17, wherein the seam iswaterproof.

19. The body panel of any of sections 13-18, wherein the border portionis curved in a direction normal to a surface plane of the planarportion.

20. The body panel of any of sections 13-19, wherein the planar portionhas a curved region proximate at least a portion of the outer edge.

21. The body panel of any of sections 13-20, wherein the border portionis asymmetrical.

22. The body panel of any of sections 13-21, wherein the border portionis positioned around all of the outer edge.

23. The body panel of any of sections 13-22, wherein the first materialis metal.

24. The body panel of section 23, wherein the metal is less than 0.6millimeters thick.

25. The body panel of any of sections 13-24, wherein the border portionis electrically conductive.

26. The body panel of any of sections 13-25, wherein the border portionis configured to visually blend with the planar portion and give theplanar portion a curved appearance.

The articles “a,” “an,” and “the” are intended to mean that there areone or more of the elements in the preceding descriptions. The terms“comprising,” “including,” and “having” are intended to be inclusive andmean that there may be additional elements other than the listedelements. Additionally, it should be understood that references to “oneembodiment” or “an embodiment” of the present disclosure are notintended to be interpreted as excluding the existence of additionalembodiments that also incorporate the recited features. For example, anyelement described in relation to an embodiment herein may be combinablewith any element of any other embodiment described herein. Numbers,percentages, ratios, or other values stated herein are intended toinclude that value, and also other values that are “about” or“approximately” the stated value, as would be appreciated by one ofordinary skill in the art encompassed by embodiments of the presentdisclosure. A stated value should therefore be interpreted broadlyenough to encompass values that are at least close enough to the statedvalue to perform a desired function or achieve a desired result. Thestated values include at least the variation to be expected in asuitable manufacturing or production process, and may include valuesthat are within 5%, within 1%, within 0.1%, or within 0.01% of a statedvalue.

A person having ordinary skill in the art should realize in view of thepresent disclosure that equivalent constructions do not depart from thespirit and scope of the present disclosure, and that various changes,substitutions, and alterations may be made to embodiments disclosedherein without departing from the spirit and scope of the presentdisclosure. Equivalent constructions, including functional“means-plus-function” clauses are intended to cover the structuresdescribed herein as performing the recited function, including bothstructural equivalents that operate in the same manner, and equivalentstructures that provide the same function. It is the express intentionof the applicant not to invoke means-plus-function or other functionalclaiming for any claim except for those in which the words ‘means for’appear together with an associated function. Each addition, deletion,and modification to the embodiments that falls within the meaning andscope of the claims is to be embraced by the claims.

It should be understood that any directions or reference frames in thepreceding description are merely relative directions or movements. Forexample, any references to “front” and “back” or “top” and “bottom” or“left” and “right” are merely descriptive of the relative position ormovement of the related elements.

The present disclosure may be embodied in other specific forms withoutdeparting from its spirit or characteristics. The described embodimentsare to be considered as illustrative and not restrictive. The scope ofthe disclosure is, therefore, indicated by the appended claims ratherthan by the foregoing description. Changes that come within the meaningand range of equivalency of the claims are to be embraced within theirscope.

What is claimed is:
 1. An electronic device comprising: a displayincluding a glass planar portion and a border portion comprised of atleast two moldable materials positioned at an outer edge of the glassplanar portion, wherein: the glass planar portion defines a majority ofa display surface, and the border portion has been molded to the outeredge of the glass planar portion and at least part of the border portionbeing curved in a direction perpendicular to the display surface,wherein the border portion is composed of a first plurality of segmentseach of a second material different from the first material and a secondplurality of segments each of a third material different from the firstand second materials, and wherein each segment of the second pluralityof segments is interposed between adjacent segments of the firstplurality of segments, and wherein the first plurality of segmentsinterlock with the second plurality of segments.
 2. The electronicdevice of claim 1, wherein each segment of the first plurality ofsegments and the second plurality of segments includes one or moreinterlocking features to facilitate the first plurality of segmentsinterlocking with the second plurality of segments.
 3. The electronicdevice of any preceding claim, wherein the display is a touch-sensitivedisplay.
 4. The electronic device of claim 3, wherein a touch-sensitiveregion of the touch-sensitive display includes at least part of theborder portion.
 5. The electronic device of any preceding claim, whereina physical button is located in the border portion or: wherein at leastone segment of the second material is coupled to electronic circuitry ofthe electronic device and configured to provide physical buttonfunctionality.
 6. The electronic device of any preceding claim, furthercomprising a radio frequency antenna, wherein at least one segment ofthe second material is a radiotransparent segment and wherein the RFantenna is located proximate the radiotransparent segment.
 7. Theelectronic device of any preceding claim, further comprising a housing,wherein the second material connects the glass planar portion to thehousing.
 8. A method of manufacturing the display of claim 1, the methodcomprising: obtaining the glass planar portion; applying the firstplurality of segments to the outer edge of the glass planar portion, thefirst plurality of segments having spaces positioned between adjacentsegments of the first plurality of segments; and after applying thefirst plurality of segments, applying the second plurality of segmentsto the outer edge, the second plurality of segments being positioned inthe spaces between the segments of the first plurality of segments,wherein the first plurality of segments and the second plurality ofsegments form the border portion of the display.
 9. The method of claim8, wherein applying the first plurality of segments includes applyingthe first plurality of segments at a first temperature; and the methodfurther comprises, before applying the second plurality of segments,allowing the first plurality of segments to cool to a secondtemperature, wherein the first plurality of segments contracts whencooling to the second temperature, and wherein the segments of thesecond plurality of segments are sized to interlock with the firstplurality of segments after the contraction.
 10. The method of claim 8or 9, further comprising priming the outer edge of the glass planarportion before applying the first plurality of segments.
 11. The methodof any of claims 8-10, further comprising preparing a lateral edge ofthe first plurality of segments before applying the second plurality ofsegments, wherein the lateral edges of the first plurality of segmentsare the edges that are for directly connecting with corresponding edgeson the second plurality of segments.
 12. An electronic device body panelcomprising: a planar body panel portion including a first material,wherein the planar body panel portion has an outer edge, a borderportion connected to the planar body panel portion along at least partof the outer edge of the planar body panel portion, the border portioncomposed of a second material different from the first material, whereinthe border portion comprises a segmented border portion, and the borderportion has been molded to the planar body panel portion, and whereinthe border portion includes: a first plurality of segments directlyconnected to the outer edge, and a second plurality of segments directlyconnected to the outer edge, wherein the first plurality of segments andthe second plurality of segments are connected to the outer edge in atleast two stages, wherein each segment of the second plurality ofsegments is interposed between segments of said first plurality ofsegments connected to the outer edge, and wherein each segment of thesecond plurality of segments meets an adjacent segment of the firstplurality of segments at a corresponding seam; and wherein at least onesegment of the border portion includes a third material different fromthe second material.
 13. The body panel of claim 12 wherein the firstplurality of segments interlock with the second plurality of segments.14. The body panel of claim 12 or 13, wherein the first material isglass.
 15. The body panel of claim 12 or 14, wherein the second materialis a polymer.